Vacuum cleaner actuator switch

ABSTRACT

A switch assembly for a wet/dry vacuum cleaner is disclosed. The switch assembly includes a switch having a movable arm to connect first and second conductive terminals with a rocker arm pivotally attached to the switch. The rocker arm is operable by an actuator button and a de-actuator button which are user engageable. Depending upon which of the de-actuator and actuator buttons are depressed, the rocker arm assumes a given position relative to the switch, which in turn results in an on or off position for the switch. An automatic shut-off assembly is operable in conjunction with the switch assembly to turn the switch to an off position in the event that the level of liquid within the tank rises beyond an acceptable level. The switch assembly enables the operator to manually override the automatic shut-off assembly.

FIELD OF THE INVENTION

The invention generally relates to wet/dry vacuum cleaners and, moreparticularly, relates to actuator switches for wet/dry vacuum cleanershaving a pumping capability.

BACKGROUND OF THE INVENTION

Wet/dry vacuum cleaners are well-known. Such devices typically include atank to which a removable lid is attached. A motor driven impeller istypically mounted within the lid to generate low pressure within thetank and thus create a vacuum for drawing matter in solid, liquid,and/or gaseous form therein.

Once the tank is filled, the user is confronted with the obstacle ofemptying the tank, which can be unwieldy and heavy once filled.Conventionally, operators are provided with two options: one, the lidcan be removed, and the tank can be tilted to empty its contents; andtwo, a drain provided at the bottom of the tank can be opened to drainthe liquid therefrom. Such a latter option is viable only in the eventthat a suitable floor drain is provided.

Recently, certain wet/dry vacuum cleaners have been provided with apumping capability. Therefore, in addition to being provided with animpeller to draw matter into the tank, a pump having an impellertypically mounted to the same motor shaft as that driving the vacuumimpeller, is provided to evacuate or discharge liquid matter from thetank. One example of such a device is disclosed in U.S. Pat. No.6,009,596 assigned to the present assignee, and expressly incorporatedherein by reference.

With such wet/dry vacuum cleaners which include pumping capability, itis important that the level of liquid within the tank does not rise tothe level of the vacuum impeller. Accordingly, such devices aretypically provided with an automatic shut-off mechanism which severspower to the motor in the event that the level of liquid in the tankexceeds a safe margin. Upon triggering the automatic shut-off, theoperator is then typically provided with an override capability whichenables the pump to discharge liquid after the user has manually removedthe vacuum intake from the source of liquid or debris.

SUMMARY OF THE INVENTION

In accordance with one aspect of the invention, a wet/dry vacuum cleanerswitch assembly is provided which includes a switch, a rocker arm, anactuator, a de-actuator, a float, and a tie rod. The switch has firstand second spaced terminals and a spring biased momentary arm. Thespring biased momentary arm is adapted to move from an on positionconnecting the first and second spaced terminals to an off positiondisconnecting the first and second spaced terminals. The rocker arm ispivotally associated with the switch and includes an engagement surfaceadapted to move the momentary arm from the off position to the onposition. The actuator is operatively associated with the rocker arm andis user engageable to move the rocker arm. The movement of the rockerarm by the actuator causes the engagement surface to move the momentaryarm from the off position to the on position. The de-actuator isoperatively associated with the rocker arm and is user engageable tomove with the rocker arm. Movement of the rocker arm by the de-actuatorcauses the engagement surface to disengage from the momentary arm, whilethe engagement of the engagement surface with the momentary arm causesthe spring biased momentary arm to move from the on position to the offposition. The tie rod is connected between the float and the rocker arm.Upward movement of the float causes the tie rod to pivot the rocker armwhich in turn causes the momentary arm to move from the on position tothe off position.

In accordance with another aspect of the invention, a wet/dry vacuumcleaner is provided which comprises a tank, a removable lid, a motor, avacuum impeller, a pump impeller, a switch assembly, a float, and a tierod. The tank has an open top with the removable lid being attached tothe open top. A motor positioned within the lid includes a shaftextending therefrom. A vacuum impeller and pump impeller are attached tothe motor shaft. The switch assembly is connected to the motor andincludes a rocker arm. The float is disposed within the tank and the tierod is connected between the switch assembly and the float.

In accordance with another aspect of the invention, a wet/dry vacuumcleaner of the type having a tank, a motor, a vacuum impeller connectedto the motor, a pump impeller connected to the motor, a switch connectedto the motor and a float assembly disposed from the tank and connectedto the switch is provided which includes a manual override switchassembly having a rocker arm, an actuator button, and a de-actuatorbutton. The rocker arm is operatively associated with the switch, theswitch includes a movable element adapted to open or close the switch.The rocker arm is adapted to move the movable element and includes firstand second ends. The actuator button is operatively associated with therocker arm first end and the de-actuator button is operativelyassociated with the rocker arm second end.

In accordance with another aspect of the invention, a wet/dry vacuumcleaner switch assembly is provided which comprises a rocker switchadapted to pivot from an on position to an off position, and a buoyantfloat connected to the rocker switch and adapted to move the rockerswitch from the on position to the off position.

These and other aspects and features of the invention will become moreapparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a wet/dry vacuum cleaner constructed inaccordance with the teachings of the invention;

FIG. 2 is a sectional, partially cut-away view of a tank, lid, powerassembly, float, and switch assembly constructed in accordance with theteachings of the invention;

FIG. 3 is a side cut-away view of a lid, power assembly and switchassembly constructed in accordance with the teachings of the inventionwith the switch assembly shown in an off position;

FIG. 4 is a side cut-away view of a lid, power assembly, and switchassembly constructed in accordance with the teachings of the inventionwith the switch assembly shown in an on position;

FIG. 5 is a side cut-away view of a lid, power assembly, and switchassembly constructed in accordance with the teachings of the inventionwith the switch assembly depicted in automatic shut-off position;

FIG. 6 is a side cut-away view of a lid, power assembly, and switchassembly constructed in accordance with the teachings of the inventionwith the switch assembly shown in an override position;

FIG. 7 is a side cut-away view of a lid, power assembly, and switchassembly constructed in accordance with the teachings of the inventionwith the switch assembly depicted in an on position with actuator andde-actuator buttons biased outwardly to the same height;

FIG. 8 is an end view of a switch assembly and an automatic shut-offassembly constructed in accordance with the teachings of the invention;and

FIG. 9 is a side view of FIG. 8.

While the invention is susceptible to various modifications andalternative constructions, certain illustrative embodiments thereof havebeen shown in the drawings and will be described below in detail. Itshould be understood, however, that there is no intention to limit theinvention to the specific forms disclosed, but on the contrary, theintention is to cover all modifications, alternative constructions andequivalents falling within the spirit and scope of the invention asdefined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, and with specific reference to FIG. 1, awet/dry vacuum cleaner constructed in accordance with the teachings ofthe invention is generally depicted by reference numeral 20. While thevacuum cleaner depicted is of a wet/dry vacuum cleaner type, it is to beunderstood that the switch assembly of the invention can be employedwith other types of vacuum cleaners and pumps as well.

As shown in FIG. 1, the vacuum cleaner 20 includes a tank 22 to which alid assembly 24 is removably attached. The lid assembly 24 includes ahandle 26 to facilitate moving the vacuum cleaner 20 as well as removalof the lid assembly 24. A plurality of casters or other types of wheels28 are attached to the tank 22 to also facilitate movement.

Turning now to FIG. 2, it can be seen that a power assembly 30 ismounted within the lid assembly 24. More specifically, the powerassembly 30 includes a motor 32 from which a rotatable shaft 34 extends.A vacuum impeller 36 is mounted to the shaft 34 with a pump impeller 38being mounted below the vacuum impeller 36. Accordingly, uponenergization of the motor 32, both the vacuum impeller 36 and pumpimpeller 38 rotate with the shaft 34. The vacuum impeller 36 is mountedfor rotation within a shroud 40. Rotation of the vacuum impeller 36within the shroud 40 creates a low pressure within the tank 22 therebydrawing matter into the tank 22.

The pump impeller 38 is mounted for rotation within a chamber 46. Thechamber 46 includes an inlet 48 and an outlet 50. An intake tube 52extends downwardly from the inlet 48 into the tank 22 and terminates ina pump intake assembly 54.

In order to energize the motor 32, a switch assembly 56 is provided. Asshown in FIGS. 3-7, the switch assembly 56 includes a switch 58 to whicha rocker arm 60 is pivotally attached at a pivot 62. The switch assembly56 also includes an actuator button 64 and a de-actuator button 66. Theactuator button 64 is mounted for reciprocating motion proximate a firstend 68 of the rocker arm 60, while the de-actuator button 66 is mountedfor reciprocating motion proximate a second end 70 of the rocker arm 60.The switch assembly 56 also includes an automatic shut-off assembly 72which includes a float 74 mounted for linear motion within a cage 76 anda tie rod 78 connecting the float 74 to the rocker arm 60.

With reference now to FIG. 9, the switch 58 is shown to include ahousing 80 from which first and second terminals 82, 84 extend. Amomentary or movable arm (not shown) is mounted within the switchhousing 80 and is adapted to move from a first or on position connectingthe terminals 82, 84, to a second or off position disconnecting theterminals 82 and 84. 20 The movable arm, and first and second terminals82 and 84 are manufactured of a suitable electrically conductivematerial, such as copper, such that when the movable arm is in the onposition, the terminals 82, 84 are connected and a circuit is completedto thereby connect a power cord 88 (FIG. 1) to the motor 32 (FIG. 2) forenergization thereof. The movable arm is preferably spring biased intothe off position. An actuator tab 90 extends from the movable armoutward through the housing 80 to engage the rocker arm 60 to engage themovable arm 86 as will be described in further detail herein. The switch58, in a preferred embodiment, is provided in the form of a Unimax modelno. TMCJG6SP0040Y switch manufactured by C & K/Unimax Inc. ofWillingford, Conn.

Referring now to FIG. 8, the rocker arm 60 is illustrated to include areceptacle 94 which receives the tie rod 78. The receptacle 94 ispreferably integrally molded with the rocker arm 60 and extendslaterally therefrom. The rocker arm 60 and receptacle 94 are preferablymanufactured from a suitable plastic, such as ABS. Extending from a topsurface 96 of the first end 68 of the rocker arm 60 is an extension arm98, as shown best in FIG. 9. The extension arm 98 serves as an extensionenabling contact of the actuator button 64 and the rocker arm 60, aswill now be described.

As shown in FIGS. 3-7, each of the actuator button 64 and de-actuatorbutton 66 is mounted within a recess 100 molded into the cover 101 ofthe lid assembly 24. The recess 100 includes an outer wall 102 and afloor 104. Each of the actuator button 64 and de-actuator button 66includes a stem 112 (FIG. 9) extending through the floor 104. In thepreferred embodiment, each of the actuator button 64 and de-actuatorbutton 66 are biased by springs 105 into an extended position away fromthe floor 104.

In operation, the switch assembly 56 and shut-off assembly 72 functionto actuate and de-actuate the vacuum motor 32 and thus the vacuumimpeller 36 and pump impeller 38. With reference to FIG. 3, the switchassembly is depicted in an off position with the de-actuator button 66depressed into the recess 100. This in turn presses the second end 70 ofthe rocker arm 60, which in turn raises the first end 68 of the rockerarm 60. In so doing, an engagement surface 118 (FIG. 9) extending fromthe rocker arm 60 pivots away from the actuator tab 90 of the switch 58.This in turn allows the biased movable arm of the switch 58 todisconnect the terminals 82, 84 to thereby open the switch 58 andde-actuate the motor 32.

When it is desired to operate the vacuum impeller 36 and/or pumpimpeller 38, the actuator button 64 is depressed into the recess 100, asshown in FIG. 4. This in turn causes the stem 112 of the actuator button64 to act upon the extension arm 98 of the rocker arm 60. In turn, thefirst end 68 of the rocker arm 60 is pivoted downwardly which in turncauses the engagement surface 118 to pivot inwardly and push theactuator tab 90 of the switch 58 inwardly. This in turn causes themovable arm to connect the terminals 82 and 84, thereby completing acircuit and actuating the motor 32.

To facilitate this motion, the engagement surface 118 includes a camsurface 120 and a locking ledge 122 which meet at a juncture 124, asshown best in FIG. 9. By providing the canted or angled cam surface 120,the engagement surface 118 is able to slide relative to the actuator tab90 while pivoting inwardly toward the switch 58 and thereby depressingthe actuator tab 90 inwardly. In order to maintain the actuator tab 90in the inward or on position, the locking ledge 122 is shaped and spacedaway from the switch 58 sufficiently to maintain the on position. Morespecifically, once the juncture 124 of the engagement surface 118 movespast the actuator tab 90, the locking ledge 122 is provided at a minimalangle to an end 126 of the actuator tab 90 such that the outward biasingforce generated by the movable arm is imparted on the angled surface ofthe locking ledge 122 while tending to pivot the rocker arm 60 in the“on” direction thus providing a minimal force of rotation to hold pivotarm 60 (against a stop) in the “on” position. In order to move theswitch assembly 56 from the on position depicted in FIG. 4, the usereither needs to manually depress the de-actuator button 66 to theposition shown in FIG. 3, or the automatic shut-off assembly 72 needs tooperate to force the switch assembly 56 into the position depicted inFIG. 5.

Operation of the automatic shut-off assembly 72 is as shown in FIG. 5,wherein the first end 68 of the rocker arm 60 has pivoted upwardly. Suchupward movement of the rocker arm 60 and first end 68 causes theengagement surface 118 to move out of contact with the actuator tab 90,which in turn moves the movable arm 86 out of contact with the terminals82 and 84, thereby de-activating the motor 32. The force causing theupward movement of the first end 68 of rocker arm 60 is generated by thefloat 74, which in turn is imparted to the rocker arm 60 by the tie rod78. As shown in FIG. 5, when the amount of liquid within the tank 22rises so as to contact the float 74, the float 74 can rise within thecage 76 with the rising liquid. The upward buoyant force generated bythe float 74 is sufficiently stronger than the frictional and rotationalforce generated between the locking ledge 122 and actuator tab 90 tothereby force the first end 68 of the rocker arm 60 upwardly.

Even after the automatic shut-off assembly 72 has functioned tode-energize the motor 32 and thereby prevent further liquid from beingbrought into the tank 22, the motor 32 can again be energized if theuser so desires. Before doing so, the user would typically remove thevacuum hose (not shown) from the source of liquid being vacuumed.Accordingly, once the motor 32 is energized, even though the vacuumimpeller 32 is rotating, only the pump impeller 38 would actually bedrawing fluid therethrough to thereby lower the level of liquid withinthe tank 22.

In order to manually override the automatic shut-off assembly 72, theuser simply depresses the actuator button 64 with sufficient force toovercome the buoyant force generated by the float 74. The operator isrequired to continually depress the actuator button 64, otherwise thebuoyant force of the float 74 again returns the switch assembly 56 tothe shut-off position depicted in FIG. 5, at least until the level offluid within the tank has dropped below the level of the float 74. Thisoverride position is depicted in FIG. 6. Once the level of liquid withinthe tank 22 has dropped below the float 74, the float 74 rests upon thebottom of the cage 76 with the tie rod 78 positioned without contactwith the rocker arm 60. This allows the switch assembly 56 to remain inthe “on” position when actuator button 64 is released (FIG. 7). As showntherein, the stems 112 of the actuator and de-actuator buttons 64 and 66rest above their respective contact portions of the rocker arm 60. Thiscan be accomplished by biasing the buttons 64, 66 upwardly by thesprings 105, and does not apply undesirable influence to rocker arm 60during operation. The actuator button 64 and the de-actuator button 66are thereby caused to be equidistantly raised within the recess 100. Theoperator can then reposition the vacuum hose for both vacuum and pumpingoperation.

From the foregoing, it can be appreciated by one of skill in the artthat the invention provides a switch assembly for a wet/dry vacuumcleaner having vacuum and pumping capability, with an automatic shut-offand manual override capability as well.

What is claimed is:
 1. A wet/dry vacuum cleaner switch assembly, comprising: a switch, the switch having first and second spaced terminals and a momentary arm, the momentary arm adapted to move from an on position connecting the first and second spaced terminals to an off position disconnecting the first and second spaced terminals; a rocker arm pivotally associated with the switch, the rocker arm having an engagement surface adapted to move the momentary arm from the off position to the on position; an actuator operatively associated with the rocker arm, the actuator being user engageable to move the rocker arm, movement of the rocker arm by the actuator causing the engagement surface to move the momentary arm from the off position to the on position; a de-actuator operatively associated with the rocker arm, the de-actuator being user engageable to move the rocker arm, movement of the rocker arm by the de-actuator causing the engagement surface to disengage from the momentary arm, disengagement of the engagement surface with momentary arm causing the momentary arm to move from the on position to the off position; a float; and a tie rod connected between the float and the rocker arm, upward movement of the float causing the tie rod to pivot the rocker arm, pivoting of the rocker arm causing the momentary arm to move from the on position to the off position.
 2. The wet/dry vacuum cleaner switch assembly of claim 1, wherein the rocker arm engagement surface includes a cam surface and a locking ledge, the cam surface facilitating movement of the rocker arm relative to the momentary arm, the locking ledge locking the momentary arm in the on position.
 3. The wet/dry vacuum cleaner switch assembly of claim 1, wherein the actuator and the de-actuator are biased into neutral positions.
 4. A wet/dry vacuum cleaner, comprising: a tank having an open top; a removable lid attached to the tank open top; a motor positioned within the lid, a shaft extending from the motor; a vacuum impeller attached to the shaft; a pump impeller attached to the shaft; a switch assembly connected to the motor, the switch assembly including a rocker arm; a float disposed within the tank; and a tie rod connected between the switch assembly and the float.
 5. The wet/dry vacuum cleaner of claim 4, wherein the switch assembly further includes a switch having first and second terminals and a movable arm, the movable arm being movable between on and off positions, the movable arm connecting the first and second terminals when in the on position, the movable arm disconnecting the first and second terminals when in the off position.
 6. The wet/dry vacuum cleaner of claim 5, wherein an engagement surface extends from the rocker arm, the rocker arm being movable between on and off positions, the engagement surface forcing the movable arm into the on position when the rocker arm is in the engagement position, the switch including a spring to force the movable arm into the off position when the rocker arm is in the off position.
 7. The wet/dry vacuum cleaner of claim 6, wherein the engagement surface includes a cam surface adjacent a locking ledge, the cam surface facilitating sliding motion of the engagement surface against the movable arm when the rocker arm moves from the off position to the on position.
 8. The wet/dry vacuum cleaner of claim 7, wherein the float is disposed within a cage disposed within the tank, the float being adapted to move linearly within the cage as the level of liquid within the tank rises and falls, movement of the float causing movement of the tie rod, rocker arm, and movable arm.
 9. The wet/dry vacuum cleaner of claim 8, further including on and off actuator buttons mounted through the lid, each button including top and bottom ends, the top ends being user engageable, the bottom ends being engageable with the rocker arm.
 10. The wet/dry vacuum cleaner of claim 9, further including springs biasing the on and off buttons away from the lid into neutral positions.
 11. In a wet/dry vacuum cleaner of the type having a tank, a motor, a vacuum impeller connected to the motor, a pump impeller connected to the motor, a switch connected to the motor, and a float assembly disposed within the tank and connected to the switch, a manual override switch assembly, comprising: a rocker arm operatively associated with the switch, the switch having a movable element adapted to open or close the switch, the rocker arm being adapted to move the movable element, the rocker arm having first and second ends; an actuator button operatively associated with the rocker arm first end; and a de-actuator button operatively associated with the rocker arm second end.
 12. The wet/dry vacuum cleaner of claim 11, wherein the switch includes a spring biasing the movable element into an open position.
 13. The wet/dry vacuum cleaner of claim 12, wherein the rocker arm includes an engagement surface adapted to move the movable element into a closed position when the rocker arm first end and actuator button are depressed.
 14. The wet/dry vacuum cleaner of claim 13, wherein the engagement surface includes a cam surface and a locking ledge, frictional interference between the locking ledge and movable element retaining the movable element in the closed position when the rocker arm first end and actuator button are depressed.
 15. The wet/dry vacuum cleaner of claim 12, wherein the actuator button and de-actuator button are biased away from the rocker arm. 